Chrysler / Dodge Minivan Service Manual
2005 - 2007 Service: Main: Local: Fax:
(866) 997-6559 (99-ROLLX) (800) 956-6668 (952) 890-7851 (952) 890-1903
Your Life. Your Ride. 6591 W. Hwy 13 Savage, MN 55378 www.rollxvans.com
TM
Chrysler / Dodge Minivan 2005 - 2007 Service Manual
#07274-007 April 2010
Table of Contents Important Item Locations....................................................................................................................... 4
Door
Rollx Power Door Trooubleshooting...................................................................................................... 8 Rollx Power Door Replacement Parts................................................................................................... 9 OEM Power Door Troubleshooting...................................................................................................... 10 Door Modifications................................................................................................................................11
Exhaust System
Exhaust System.................................................................................................................................. 15
Exterior
Exterior - Ground Effects..................................................................................................................... 18
Fuel System
Fuel System........................................................................................................................................ 19
Interior
Interior................................................................................................................................................. 27
Kneeler
Kneeler Troubleshooting..................................................................................................................... 30 Kneeler Replacement Parts................................................................................................................ 31 Kneel Switch Adjustment Process....................................................................................................... 32
One Touch System
One Touch System Troubleshooting.................................................................................................... 35 One Touch System Overview.............................................................................................................. 36 One Touch System - v6.0 Interface..................................................................................................... 38
Ramps
In The Floor (Gas Spring) Troubleshooting......................................................................................... 44 In the Floor (Gas Spring) Replacement Parts..................................................................................... 45 In The Floor (Metal Springs) Troubleshooting..................................................................................... 46 In The Floor (Metal Springs) Replacement Parts................................................................................ 47 Folding Ramp Troubleshooting........................................................................................................... 48
Page
Table of Contents Folding Ramp Replacement Parts...................................................................................................... 49 Folding Ramp Adjustment Process..................................................................................................... 51 Folding Ramp Motor Install / Ramp Removal Instructions.................................................................. 52
Rear Heat & Air
Rear Heat & Air................................................................................................................................... 54
Suspension
Suspension.......................................................................................................................................... 55
Wiring
OTC System - 6.0 After 3/21/07.......................................................................................................... 56 OTC System - 4.05 and 6.0 Before 3/21/07........................................................................................ 58 Passenger Door Snake - In The Floor Ramp (#07017-001)................................................................ 60 Passenger Door Snake - Folding Ramp (#07018-001)....................................................................... 62 Rollx Power Door System................................................................................................................... 64 Occupant Control Module / Seat Sensor Resistors............................................................................. 66 Power Seats - Driver with Power Only................................................................................................ 67 Power Seats - Driver with Power and Heat......................................................................................... 68 Power Seats - Passenger with Power and Heat................................................................................. 69 Power Seats - Driver with Memory...................................................................................................... 70
Maintenance Information
Maintenance Information..................................................................................................................... 72
Warranty
Warranty.............................................................................................................................................. 73
Page
Important Item Locations OEM Main Wire Harness Rollx Main Wire Harness
OTC Remote Receiver Occupant Control Module / Seat Sensor Resistors Main Fuse
ITF Ramp Access Panel
Power Seat Connector
OTC Relay Panel
OTC Door Control Relay (OTC Door Disable) OTC Fuse Panel (Under Glove Box)
OTC Controller Board Kneeler
ITF Door Open Switch Rear Heat Rear AC
Page 4
Important Item Locations Occupant Control Module (OCM)
OTC Remote Receiver
OEM Wire Harness 1
OEM Wire Harness 2
Rollx Main Wire Harness 1
Rollx Main Wire Harness 2
Page
Important Item Locations Main Fuse
OTC Fuse Panel (Under Glove Box)
ITF Door Open Switch
ITFRamp Access Plate
Rear Heat
Rear AC
Page
Important Item Locations OTC Relay Board
Kneeler and OTC Control Board
Kneeler Cover
Power Seat Connector
OTC Door Control Relay
Page
Rollx Power Door Trouble Shootings * If remote does not work first try to operate door and ramp from any interior Rollx user button. If interior Rollx user button operates normally, see below for remote system troubleshooting Symptom
Door does not open when One Touch remote is pressed.
Neither One Touch remote works. OTC Remote Receiver (Before 1/8/2009)
Possible Cause
Remedy
Receiver out of range.
Try remote within 10 feet of van.
Overhead on/off switch is turned to the OFF position.
Turn switch to ON position.
Remote battery is dead.
Remove case by loosening screw on back and prying open. Replace battery with battery type A23. Use second remote or Rollx user button.
Remote lost its program
Reprogram remote with receiver or install new chip (all receivers with #910R-08 sticker on the chip have the possibility of needing replacement. Call Customer Service..
Blown fuse.
Locate fuse box under glove box and check / replace fuse.
Receiver malfunction.
Review display on OTC board and contact customer service.
OTC Remote Receiver (Rear View)
OTC Remote Transmitter Opened
OTC Remote Receiver (After 1/8/2009)
A23 Battery
Red LED Indicator Light
Each Rollx Transmitter has a unique code. These codes are applied to the transmitter either by a trace cutting method or a DIP switch programming method. This is normally done at the Rollx Factory. In order to program the transmitter(s) to the receiver the following process must be done. Learning a New Button Code (channel 1) 1. Press mode switch #1 for three seconds. The green LED will start to flash quickly. If no green LED lights, ensure power is getting to the unit through the 1 Amp fuse in the Rollx Fuse Panel. 2. While the green LED is flashing quickly, press a button on a compatible transmitter. The green LED will flash once and then turn off to show that button was learned. 3. Repeat steps 1 and 2 to learn more buttons into channel 1. NOTE — The green LED will flash a maximum of 15 seconds. If no transmitter button is pressed during this time, the receiver will exit the code-learning mode, and the green LED will turn off. Note Regarding Code Learning 1. The receiver will only learn the code of a particular button once. Once a button’s code is learned, if you try to code-learn that button again, whether it is for the same channel or not, the receiver will exit code learning mode. 2. Each channel can learn the codes of a maximum of 15 transmitter buttons. If you attempt to learn a sixteenth button, the earliest code learned will be deleted. 3. To clear all codes — Press the appropriate mode switch (#1 or #2) for three seconds. When the LED starts flashing, press that switch again for three seconds. The LED flashes twice to indicate that all codes associated with that channel are now deleted. *From SECO-LARM Manual
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Page
2 3 4 5
1 1 1 1
Item Qty. 1 1 1 1 1 1
15
8
11
4
10 9
Description Part # DOOR BAR ASM (INCLUDES THE 3 FOLLOWING) 10026ASM MTR BAR DOOR OPENER (RACK AND ASSEMBLY) 10026 WIRE HARNESS 5.5" FOR 310-1059 MTR 12V 10NM 10MM DOUBLE 210-1011 GEAR RACK (SPECIFY LONG OR SHORT)* 10026-4 LONG BAR 1126318 3/8 X 1 STRIP ARM BAR (FOR MOTOR BAR) 10026-22 WIRE HARNESS 5.5" FOR 310-1059 10026-15ASM MOTOR ONLY W/GEAR ASM (INCLUDES WIRE HARNESS AND SHIMS**) * LONG USED BEFORE ~2001 IF NO REAR HEAT & AIR ** SHIMS ONLY NEEDED IF BEFORE ~2003 BUT ALWAYS SENT WITH MOTOR
1
2
17
3
Item Qty. 6 1 7 1 8 1 9 1 10 2 11 N/A 12 N/A 13 2 14 1 15 1 16 1 17 2 18 1
5
16
18
6
13 7
Description BRKT MTR BAR LIMIT SWITCH SWITCH DPDT (CHERRY) HANDLE CHROME INSIDE DOOR BRACKET A (DOOR BRACKET B - ) DOOR ARM PLATE MANUAL RELEASE TENSION ADJUSTMENT 1/4-20 NYLOCK NUT #6 NYLOCK NUT 1/4-20X3/4 HEX HEAD SCREW 5/8-20X1 HEX HEAD SCREW (ADJUSTMENT) SHIM KIT FOR DOOR OPENERS (INCLUDES ALL 3 - VARYING SIZES) #10-32X2 HEX HEAD (5/32) PARTIALLY THREADED SCREW #10-32X2-1/2 HEX HEAD (5/32) PARTIALLY THREADED SCREW (NUT ON BACK)
12
14
12
COM
COM
Part # MB1006 E19-50H 6022 MB1001 (MB1002) MB1005 NA SHOP SUPPLY SHOP SUPPLY SHOP SUPPLY SHOP SUPPLY 10026-12 SHOP SUPPLY SHOP SUPPLY
NC NO NC NO
Rollx Power Door Exploded View
R Rollx ollx P Power ower D Door oor Replacement eplacement Parts
OEM Power Door Troubleshooting Symptom
Possible Cause Van is NOT in park or neutral. Overhead on/off switch is turned to the OFF position. OTC program failure
Remedy Place van into park or neutral. Turn switch to ON position. Press OTC reset button.
OTC reads low voltage.
Start van's engine and press OTC reset button. If door still does not open review OTC board display and contact customer service.
Relay power fuse (1 amp) is blown.
Replace fuse in OTC fuse panel located behind glove box.
Bad OTC board.
Watch the Door Control Status LED as you start an Open Cycle. It should light for about one second at which time you should see the door open. If it does not, replace the OTC board.
B-pillar door control relay is bad.
Check the Door Control Relay located in the BPillar. Wrap you hand around the relay and start an Open Cycle. You should feel the relay operate with your hand when the Door Control LED lights. If you do not, replace the relay.
Main OTC fuse (40 amp) is blown.
Replace fuse under by battery.
OEM overhead ON / OFF switch is OFF
Turn switch to ON position. This switch enables / disables the OEM buttons located on the B pillars that operate the sliding doors,
Defective OEM door opener.
Operate door manually and contact customer service.
OEM Door Ajar Pin Switch (Rollx Door Close signal) is not released.
If the OTC does not see the OEM door has begun to open it will reverse the cycle. Examine switch / wiring.
Ramp up limit switch is not being activated properly.
Close door manually, press OTC reset button, and press Rollx user button to operate system again. If door still does not attempt to close after ramp is stowed, review OTC board display and contact customer service.
Ramp sliding door attempts to close (door motor runs) after ramp stows, but door does not move
Defective OEM door opener
Press OTC reset button, press interior OEM push button to see if door will close automatically. If door still does not respond, review OTC board display and contact customer service
Ramp sliding door does NOT OPEN manually.
Door is locked.
Unlock door. When pulling door handle, pull handle out and then slide door to open.
Ramp sliding door does NOT OPEN manually from interior handle, but does from exterior handle.
Child safety lock is activated.
See OEM owner manual to deactivate child safety lock.
Door handle is not releasing.
Pull handle to disengage latch and slide to close.
Obstruction.
Check door track for any debris and remove.
Passenger sliding door does NOT OPEN with interior Rollx user button.
Ramp sliding door does NOT OPEN with interior OEM push buttons after pressing OTC reset button.
While door is opening and kneeling, van unkneels and door closes (reverses). Ramp sliding door does NOT attempt to CLOSE after ramp stows.
Ramp sliding door will NOT CLOSE manually.
Door open drive mechanism has moved beyond Lift rear section of door while pressing forward to stop bracket. release door. Contact customer service.
Page 10
D Door oor M Modifications odifications
Door Extensions #10002 Passenger #10001 Driver
Install T nuts (STD)
Form door extensions. Grind to smooth transitions. Install door extensions using rivets
Install T nuts (ITF)
Install angle bracket using rivets. #10504—1x1 x 14 gauge angle (mounted on outside of extension) *
Door track installed with factory bolts. Extension attached with 3/16 rive as shown.
*Starting 8/11/2009 the Metal Angle Bracket was replaced by a Plastic Angle Bracket. Refer to Service Bulletin #09168 (Order Qty 1 #B08180-DP6, Qty 5 #10269 – 3/16 Rivets per door, each with #1133074 - #10 Washer)
Page 11
Door Modifications Door open brackets on driver and passenger door tracks
Power Doors In the Floor vans: Passenger #N05028ASM Driver #N05029ASM Fold Out vans: Passenger #B2032 Driver #BRKT-LDTDS Manual Door Driver #BRKT-LDTPS-MANUAL
Door cables for Fold Out and In The Floor vans
Door open latch cable In the Floor vans: OEM cable Fold Out vans: Non power door # AV-100 Power door #AV-100P
Door drive cable Power door only: PX3879BR
Page 12
Door oor Modifications 10” In The Floor only Weld latch open. Install latch to door spaced out with washers. Relocate door drive motor.
Weld latch as shown in the open position
Relocate motor and wire as shown.
Page 13
Door Modifications Fold out ramps only Drill hole and add rivet main plate on door open latch. The rivet stops the latch when locked by latch lock.
Door open latch and switch
Latch lock Rivet
Rivet
OEM Hold Open Latch ASM: RT - #68030816AA LT - #68030817AA
Page 14
Exhaust System Rollx Weld OEM Catalytic Converter / O2 Sensor
OEM Hanger
Rollx Exhaust #32-3 (Aluminized Tubing)
Rollx Exhaust #32-3 (Aluminized Tubing)
Page 15
Exhaust System Rollx Weld
Rollx Exhaust #32-3 (Aluminized Steal Tubing) OEM Hanger Rollx Exhaust #32-2 (Aluminized Steal Tubing)
OEM Hanger
Rollx Exhaust #Lease 13 (Aluminized Steal Tubing) Rollx Weld
Rollx Muffler #1224 (Aluminzed Steal Tubing)
Page 16
Exhaust System
Rollx Weld OEM Hanger OEM Resonator and Tail Pipe Rollx Exhaust #Lease 13 (Aluminized Steel Tubing)
Page 17
Exterior - Ground Effects
B05150-P4
B05150-P3
B05150-D1
B05150-P2
B05150-D2
Page 18
B05150-P1
B05150-D3
B05150-D4
Fuel System
Rollx Fuel / Emission System Overview OEM Fuel Quick Disconnect To Engine
Rollx Main Fuel Metal Line (5/16) Rollx Charcoal Canister Vent Hose OEM Charcoal Canister
Pre-modified OEM Setup
Rollx Charcoal Canister Vent Metal Line
Rollx Main Fuel Metal Line (5/16) Rollx Main Fuel Line (5/16) Rollx Main Fuel Line Adapter (3/8 to 5/16)
OEM Filler Neck Top (Gas Cap)
Rollx Filler Neck Hose
OEM Fuel Fill Vent Line
Rollx Main Fuel Line (3/8)
Rollx Fuel Fill Vent Line
OEM Fuel Tank
Rollx Charcoal Canister Vent Hose
OEM Fuel Pump / Oem Fuel Filter
Page 19
Fuel System OEM Fuel Filler Neck (Gas Cap) OEM Fuel Fill Neck OEM Fuel Fill Vent Line
Rollx 9/16 Clamp #OET 1315 (OETIKER 9/16 CLAMP)
Rollx Fill Neck Extension #B05102 (Aluminized Steel Tubing) Rollx Filler Neck Hose #049020201 (1-1/4 2BD Redwing Fuel by Goodyear)
Rollx 1-1/2 Hose Clamp #705-1017 Rollx Fuel Fill Vent Hose #10929-00832 (5/16 Fuel/Emissions Hose,SAE 30R7, Goodyear) Rollx welds a Fill Neck Extension onto OEM Fuel Fill Neck to extend the OEM Fuel Fill Neck to the Rollx Filler Neck Hose. The modified filler neck is smoke tested for possible pin hole leaks. Rollx’s Fill Neck Extension is clamped to the Rollx Filler Neck Hose. Rollx attaches a Fuel Fill Vent Hose that begins at the gas tank to the OEM Fuel Fill Vent Line with a 9/16 clamp. This hose is routed underneath the frame.
Page 20
Fuel System Rollx Main Fuel Hose #H-212 (3/8 Fuel Injection Hose,SAE 30R9,180 PSI,WP, CARB #c-u-06-002, Gates Corp.)
OEM Clamp
Rollx Charcoal Canister Vent Hose #10929-00834 (5/8 Fuel/Emissions Hose, SAE 30R7, Goodyear)
OEM Clamp
Rollx Fuel Fill Vent Hose #10929-00832 (5/16 Fuel/Emissions Hose,SAE 30R7, Goodyear)
Rollx Clamp #OET 1315 (5/16)
Tank Fuel Intake Rollx Main Fuel Hose #H-211 (5/16 Fuel Injection Hose,SAE 30R9, 180 PSI,WP,CARB #c-u-06-002, Gates Corp.)
Fuel Line Adapter (3/8 to 5/16) #10929-0824 with two Rollx clamps #OET 1518 (3/8) + #OET 1315 (5/16)
Rollx reuses the OEM Gas Tank. Rollx replaces OEM Fuel Fill Vent Hose with Rollx Fuel Fill Vent Hose that is 48 inches long and runs to OEM Fuel Vent Line near Filler Neck top (Gas Cap). Rollx replaces OEM Charcoal Canister Vent Hose with Rollx Charcoal Canister Vent Hose that runs to Rollx Charcoal Canister Vent Metal Line. Rollx replaces OEM Main Fuel Hose with Rollx Main Fuel Hose that begins with 3/8 inch high pressure hose, goes through an adapter, changes to 5/16 high pressure hose and runs to Rollx Main Fuel Metal Line where it is clamped with a Rollx Clamp after being flared.
OEM Clamp
Rollx Charcoal Canister Vent Metal Line #B2103 (5/8 x .049 3003-0 Aluminum)
Rollx Filler Neck Hose #049020201 (1-1/4 2BD Redwing Fuel by Goodyear)
To Charcoal Canister To Engine
Rollx Clamp #OET 1315 (5/16) Rollx Main Fuel Metal Line #126229 (5/16 x .028 Fusion, Weld Procoat, J526)
Page 21
Fuel System
Rollx 1-1/2 Hose Clamp #705-1017
Attach Rollx Filler Neck Hose to OEM Fuel Tank with Rollx Clamp as shown.
Page 22
Fuel System Rollx attaches their metal lines to the floor using 1 inch Rubberized Metal Clamps.
Rollx Main Fuel Metal Line (5/16)
Rollx Charcoal Canister Vent Metal Line (5/8)
Rollx Clamp #770-1162 (1” Rubberized Metal Clamp
Page 23
Fuel System Rollx Main Fuel Metal Line (5/16)
Rollx Charcoal Canister Vent Hose #10929-00834 (5/8 Fuel/Emissions Hose, SAE 30R7, Goodyear)
OEM Clamp
Rollx Charcoal Canister Vent Metal Line (5/8)
Rollx metal lines continue underneath the driver’s side of the van as shown. The Rollx Charcoal Canister Vent Metal Line is clamped using an OEM Clamp onto the Rollx Charcoal Canister Hose. The Rollx Main Fuel Metal Line continues toward the OEM Quick Disconnect on the OEM Fuel Rail.
Rollx Main Fuel Metal Line (5/16)
Rollx Charcoal Canister Vent Hose #10929-00834 (5/8 Fuel/Emissions Hose, SAE 30R7, Goodyear)
OEM Clamp to OEM Charcoal Canister The Rollx Charcoal Canister Hose is routed up to the OEM Charcoal Canister and attached with an OEM Clamp.
Page 24
Fuel System
Rollx Main Fuel Metal Line (5/16)
Rollx Main Fuel Metal Line continues along the OEM frame and is routed as shown.
OEM Fuel Quick Disconnect
Rollx Main Fuel Metal Line (5/16)
Rollx flares the Rollx Main Fuel Metal Line and attaches to the Oem Fuel Quick Disconnect as shown.
Page 25
Fuel System
Rollx Charcoal Canister Bracket #B1040 Rollx relocates the OEM Charcoal Canister as shown using Rollx Charcoal Canister Bracket. The canister is moved slightly towards the center of the van as well as being rotated 90 degrees.
Page 26
Interior
Slate Grey #B2204 Grey Stone #B2204-GS Khaki #B2204-K
Slate Grey #B2202 Grey Stone #B2202-GS Khaki #B2202-K
Slate Grey #B2200 Grey Stone #B2200-GS Khaki #B2200-K
Slate Grey #B2201 Slate Grey #B2203 Grey Stone #B2201-GS Grey Stone #B2203-GS Khaki #B2201-K Khaki #B2203-K
Tire cover
Kneeler Cover
Page 27
Interior Power seat and heated seat connectors assemblies (include plug, pins, ad wires) Seat side assembly #07079-003 Body side assembly #07079-004 Power seat only connector assemblies Seat side assembly #07079-001 Body side #07079-002 Memory seat connectors assemblies (if equipped) Seat side assembly #07079-005 Body side assembly #07079-006 Main base includes all parts Minivan #4003std Full size #4003full Foot rest #10033 Front dog bone hook Rod end Connecting rod Cross bar
Latch handle #56030 Caster wheel
Page 28
Page 29
Kneeler Troubleshooting Symptom Van does NOT LOWER to ground while door is opening after Rollx user button is pressed. After van is lowered to ground the kneeler makes a loud ratcheting sound.
Van will NOT RAISE when ramp is stowed.
Van raises and while door closing the kneeler ratchets.
Possible Cause
Remedy
Kneel on / off switch is turned OFF.
Turn kneel switch to the ON position.
Kneel motor.
Review display board. Turn kneel switch to the OFF position and press OTC reset button. Temporarily operate sytem without kneel option enabled. Contact customer service.
Kneel down limit switch was not activated.
Adjust kneel down limit switch. Replace if broken.
Kneel on / off switch is turned OFF.
Turn kneel switch to the ON position.
Kneel motor .
Review display board. Manually unkneel van, turn kneel switch to the OFF position and press OTC reset button. Contact customer service.
Kneel up limit switch is activated incorrectly.
Adjust kneel up limit switch. Replace if broken.
Kneel up limit switch is not activated.
Once door is closed and van is at normal height, turn kneeling switch to the OFF position.
Page 30
Item 1 2 3 3A 4 5 6 7 8 9 10 11 12 13 14
Page 31
1 1 0.17 1
Qty. 1 2 1 1.5 1 1 2 1 1 1 2 3 4 4 1
Description Part # K2XG20-12V-08RX-ASM ACTUATOR KNEELING ASM 626AK194 50 CONN LINK 6261K534ASM KNEEL CHAIN ASM 6261K534 CHAIN 50 ROLLER K05012 KNEEL CHAIN SWIVEL 98338A220 COTTER PIN 10FDU06 FLANGE BRG LTR-075M-6-2ASM SPRING TORSION ASM 6280K249 SPROCKET FOR #50 CHAIN 03220-003 KNEEL LIMIT SWITCH ASM 6X284 SWITCH TANG BZ-2RW80-A2 3/8-16X1 HEX BOLT SHOP SUPPLY #6X1 PH SELF TAPPING SCREW SHOP SUPPLY #10 NYLOCK NUT SHOP SUPPLY K05006ASM ACTUATOR GUIDE ASM Parts on Van (Not Shown) 800-0072 RATCHET REVERSIBLE 4PW71 SOCKET 3/8" AL200 ALUM PIPE 2'X10' 152303 BOOT BLK "2005" KNEELACT
1
13
11
11
7
2
9
10
12
3
6
3A
8
6
5
2
4
Service #KNEEL SNG OT-01 - KNEEL OTC SNG COMPLETE ASM
14
Kneeler Replacement Parts
Tools Required: Grease Pen Retro Kit: R0013
Revision Date: 8/1/04
Kneel Switch djustment Process Time to A Complete: 20 Minutes
Adjustment Process: 1.
Remove floor section located in rear of vehicle on passenger side.
2. Remove Remove screws located at theinfront tire cover located rearand of rear of the actuator cover (located in rear of vehicle. vehicle under back passenger seat). Remove cover.
3.
Using the O.T.C. (located Remove kneeler cover.in the rear of the vehicle on the passenger side), manually lower the van until the snubber on the passenger side touches the axle.
4.
Mark the actuator arm and base with a grease pen where the arm assembly sits in the base (figure REV-118).
5.
Using the O.T.C. manually raise vehicle so actuator arm moves about 1" (this is to allow to bend the limit switch arm).
6.
1”
Bend limit switch arm as shown at right.
Page 32
Kneel Adjustment Process
Kneelcontinued Switch Adjustment Process
7.
Adjust limit switch arm by hand so that when the switch is triggered (kneeling stops) the actuator arm lines up with the mark made on the base.
8.
Extend actuator to its full-extended position (vehicle will be raised). Back off about 1/4" and mark arm's position on actuator base as in step 4.
9.
1 1/4”
Back arm off 1" to allow for limit switch adjustment.
10. Bend limit switch arm as shown in figure REV-119 .
11. Adjust limit switch arm by hand so that when the switch is triggered (kneeling stops) the actuator arm lines up with the mark made on the base.
12. Run the actuator to its full extension. Bring actuator back to its full retracted position.The limit switchs should not catch or bend during this process.
Page 33
Kneel Adjustment Process Kneel Switch Adjustment Process continued
13. Repeat previous step a couple times to ensure that the actuator stops when the arm is at the mark made in step 4.(If the limit switch is bending out place add more of a curve to the end and retry 6,7 and 8.) 14. Replace actuator cover.
15. Replace floor section removed earlier.
Page 34
One Touch System Troubleshooting Symptom
Remedy Check that OTC power switch is on. For OTC v6.0 boards the power switch is on the actual board. For v4.02 to v4.05 boards, the switch is located on the dash by the drivers left knee.
No power to One Touch Controller (OTC).
Insure the connections on the back of the OTC board are tight. Check the OTC main fuse (40 amp) located near the vehicles main battery. Reset the OTC. For OTC v6.0 boards the reset is located on the dash by the drivers left knee. For 4.02 to 4.05 boards reset by turning the On/Off switch by the drivers left knee Off (O) for 60 seconds, then back On (I). Check battery voltage.
OTC beeps 4 times each time the user tries to run a normal open/close cycle.
Battery is low. Turn off the OTC and charge battery. Note: The alarm will sound when the battery voltage receaches below 11.4 vdc. The is to prevent the OTC system from draining the battery far enough as to prevent the vehicle from starting. On the OTC v6.0 board, this level is adjustable. Van has been sitting for an extended period of time. Charge the battery.
The van's battery is dead.
Check the current draw by placing an ammeter in series with the negative terminal on the battery with all doors closed and engine off. The draw varies, but awake the system should be less than .850 amps and when sleeping, less than .050 amps. Additional equitpment installed will also vary these numbers.
OTC beeps 3 times, pauses, and beeps 2 Ramp limit switch was missed during last cycle. Check to make times over and over. sure both ramp limit switches are adjusted properly. OTC beeps 3 times, pauses, and beeps 3 Kneel limit switch was missed during last cycle. Check to make times over and over. sure both kneel limit switches are adjusted properly. For a OTC v4.05 to 6.0 the door unlock relay is built into the board. Replace board. Doors do not unlock when using a Rollx For a 4.02 to 4.04 board, check the relay power fuse located on user button. the OTC fuse panel behind the glove box. Also check the relay located ontop of the dash on the passenger side.
3 Beeps - Pause - 1 Beep 3 Beeps - Pause - 2 Beep 3 Beeps - Pause - 3 Beep 3 Beeps - Pause - 4 Beep 3 Beeps - Pause - 5 Beep 3 Beeps - Pause - 6 Beep 4 Beeps - 4 Beeps - 4 Beeps
Alarm Warning Codes
Sliding Door Error Kneel System Error Ramp System Error Memory Error Com Error Power Supply Error Low Battery Voltage
Page 35
One Touch System Overview
Page 36
One Touch System Overview INPUTS Note: Input Status LEDs are all green in color on the v4.02 to v4.05 OTC boards. KNEEL DISABLE SWITCH (Violet wire) Allows the user to enable (the “I” position) or disable (the “O” position) the kneeling system. There is no display for this input. USER SWITCH INPUT (Blue wire) Active while any Rollx user button or Rollx remote is pressed. IGNITION INPUT (Pink/White wire) Indicates the status of the van ignition switch. When active it indicates the ignition switch is off and the OTC will go into sleep mode when not in use. When not active it indicates the van ignition switch is on and the OTC will not go into sleep mode. NEUTRAL INPUT (Green wire) Indicates the status of the gear shifter. When active, the van is in either neutral or park. The OTC system will not run a operational cycle unless the van is in neutral or park. DOOR CLOSE LIMIT INPUT (Violet/Yellow wire) Active when the right side sliding door is fully shut. DOOR OPEN LIMIT INPUT (Orange/Red wire) Active when the right side sliding door is fully open. RAMP DOWN LIMIT INPUT (Red/White wire) Active when the ramp is in the down position. RAMP UP LIMIT INPUT (Red/Green wire) Active when the ramp in the up position. KNEEL DOWN LIMIT INPUT (Yellow/Green wire) Active when the kneeler is in the down position. KNEEL UP LIMIT INPUT (Yellow/White wire) Active when the kneeler is in the up position. OUTPUTS Note: Output status LEDs are all red and yellow in color on the v4.02 to v4.05 OTC boards. System Status: Indicates if the system is ready to except a command. It is off when the OTC is in sleep mode. V4.02 to v4.05 - LED will normally be flashing on and off when the OTC is in Idle Mode. v6.0 - Display will show Rollx Vans: Idle. RAMP DOWN MOTOR OUTPUT (Red wire) Active when the OTC is driving the ramp down (v4.05 and v6.0 OTC boards have obstacle detection monitoring this output). RAMP UP MOTOR OUTPUT (Red/Black wire) Active when the OTC is driving the ramp up (v4.05 and v6.0 OTC boards have obstacle detection monitoring this output). RAMP DISABLE OUTPUT (Red/Blue wire) Active anytime when the OTC is driving the ramp up or down. It indicates the ramp manual mode is disabled. KNEEL UP MOTOR OUTPUT (Yellow/Red wire) Active when the OTC is driving the kneeler up. KNEEL DOWN MOTOR OUTPUT (Yellow/Black wire) Active when the OTC is driving the kneeler up. DOOR DISABLE OUTPUT (Orange/Blue) Used by the OTC to disable the Chrysler right side door controller anytime it wants to open the ramp. This prevents the right side door controller from banging the right side sliding door against the ramp. DOOR CONTROL OUTPUT (Orange) OTC sends a command to the Chrysler system to open or close the right Side sliding door (LED on v4.02-v4.05 OTC boards lights for about one second). DOOR UNLOCK OUTPUT (Yellow/Brown ) OTC sends a command to the Chrysler system to unlock the doors at the beginning of an open cycle (LED on v4.02 to v4.05 OTC boards lights for about one second).
Page 37
One Touch System - v6.0 Interface
Page 38
One Touch System - v6.0 Error Codes
Page 39
One Touch System - v6.0 Error Codes
Page 40
One Touch System - v6.0 Error Codes
Page 41
One Touch System - v6.0 Error Codes
Page 42
One Touch System - v6.0 Error Codes
Page 43
In The Floor (Gas Spring) Troubleshooting Symptom
Possible Cause
Remedy When a Open Cycle starts, the OTC will send a command to the Chrysler System to unlock the doors. It then sends a second command to the Chrysler System to open the Right Side Sliding Door. The OTC Computer then waits two seconds and checks the Door Closed Limit Switch. If it finds it still indicates the door is closed, it assumes that a person (or and obstacle) stopped the door opening sequence. It then ends the open cycle and goes back into Idle Mode. After ten to fifteen seconds it goes back into Sleep Mode. This is the sequence of events you will see if the Door Closed Limit Switch malfunctions (sticks closed). This switch is located in the towards the rear of the lower door track.
Door open limit switch is not being activated.
Ramp will NOT DEPLOY after door opens automatically.
Ramp will NOT STOW automatically.
Ramp motor not engaged.
Engage ramp motor. Refer to the “Manual Operation” section of owner’s manual.
Ramp down limit switch needs adjustment to deactivate.
Press Rollx user button again to unkneel van and close door. Review display on OTC board and contact customer service.
Ramp motor.
Review display on OTC board and contact customer service.
OTC program failure.
Press OTC reset button.
Ramp motor not engaged.
Engage ramp motor. Refer to the “Manual Operation” section of this manual.
Ramp motor.
Review display on OTC board and contact customer service.
Low voltage from the battery.
Start vehicle. Press OTC reset button and press Rollx user button again.
Gas spring is not assisting ramp to stow.
Assist ramp in early phases of stowing by pushing ramp in. Contact customer service. Clear obstruction and press Rollx user button.
Ramp will STOP AND REVERSE mid-cycle.
Obstacle is detected.
Ramp will start to deploy or stow then stop functioning.
Pressure on cover plate.
Page 44
Review display on OTC board and contact customer service. Ensure that there are no objects on top of cover plate.
In the Floor (Gas Spring) Replacement Parts
Page 45
In The Floor (Metal Springs) Troubleshooting Symptom
Possible Cause
Remedy
Door open limit switch is not being activated.
When a Open Cycle starts, the OTC will send a command to the Chrysler System to unlock the doors. It then sends a second command to the Chrysler System to open the Right Side Sliding Door. The OTC Computer then waits two seconds and checks the Door Closed Limit Switch. If it finds it still indicates the door is closed, it assumes that a person (or and obstacle) stopped the door opening sequence. It then ends the open cycle and goes back into Idle Mode. After ten to fifteen seconds it goes back into Sleep Mode. This is the sequence of events you will see if the Door Closed Limit Switch malfunctions (sticks closed). This switch is located in the towards the rear of the lower door track.
Ramp motor not engaged.
Engage ramp motor. Refer to the “Manual Operation” section of owner’s manual.
Ramp down limit switch needs adjustment to deactivate.
Press Rollx user button again to unkneel van and close door. Review display on OTC board and contact customer service.
Ramp motor.
Review display on OTC board and contact customer service.
OTC program failure.
Press OTC reset button.
Ramp motor not engaged.
Engage ramp motor. Refer to the “Manual Operation” section of this manual.
Ramp motor.
Review display on OTC board and contact customer service.
Low voltage from the battery.
Start vehicle. Press OTC reset button and press Rollx user button again.
Ramp will NOT DEPLOY after door opens automatically.
Ramp will NOT STOW automatically.
Ramp will STOP AND REVERSE mid-cycle.
Obstacle is detected.
Ramp will start to deploy or stow then stop functioning.
Pressure on cover plate.
Page 46
Clear obstruction and press Rollx user button. Review display on OTC board and contact customer service. Ensure that there are no objects on top of cover plate.
In The Floor (Metal Springs) Replacement Parts
Page 47
Folding Ramp Troubleshooting Symptom
Ramp will NOT DEPLOY after door opens automatically.
Ramp will NOT STOW automatically.
Ramp will STOP AND REVERSE mid-cycle.
Possible Cause
Remedy
Ramp fuse or circuit breaker is blown.
Press Rollx user button again to unkneel van and close door. Reset circuit breaker or check ramp fuse and replace if needed with 15 amp glass fuse located in glove box.
Door open limit switch is not being activated.
When a Open Cycle starts, the OTC will send a command to the Chrysler System to unlock the doors. It then sends a second command to the Chrysler System to open the Right Side Sliding Door. The OTC Computer then waits two seconds and checks the Door Closed Limit Switch. If it finds it still indicates the door is closed, it assumes that a person (or and obstacle) stopped the door opening sequence. It then ends the open cycle and goes back into Idle Mode. After ten to fifteen seconds it goes back into Sleep Mode. This is the sequence of events you will see if the Door Closed Limit Switch malfunctions (sticks closed). This switch is located in the Right Side Sliding Door Latch Assembly.
Ramp down limit switch needs adjustment to deactivate.
Press Rollx user button again to unkneel van and close door. Review display on OTC board and contact customer service.
Ramp motor.
Press Rollx user button again to unkneel van and close door. Review display on OTC board and contact customer service.
OTC program failure.
Press OTC reset button.
Ramp fuse or circuit breaker is blown.
Press Rollx user button again to unkneel van and close door. Reset circuit breaker or check ramp fuse and replace if needed with 15 amp glass fuse located in glove box.
Ramp motor.
Review display on OTC board and contact customer service. Clear obstruction and press Rollx user button.
Obstacle is detected.
Page 48
Review display on OTC board and contact customer service.
Page 49
Item 1 2 3 4 5 6 7 8 9 10 11 12
11
2
3
8
10
9
Description MOTOR RAMP (Does not include connector (OTC only) CAM FOR PICK UP ARM ALUM #8-32X1/4 CUP POINT SET SCREW ROLLER CROWNED YOKE 5/16-18 X 1-1/4 BHSCS 5/16-18 X 1-1/4 FHSC BEARING/BUSHING RAMP LIMIT SWITCH ASM SWITCH MINI SNAP ACTING SWITCH SPACER STD RAMP S/S PPHMS 4-40X1 1/2 #4 sae 5/16od z f/w
12
Qty. 1 2 2 1 1 4 1 1 2 1 2 2
1
19
18
Part # K01325A350 RLXRP00CAM-ALUM N/A CY36L 1124072 1124257 SF-2432-8 03220-004 7779K62 RLXRPOO-14 72498 1133066
6
Item 13 14 15 16 17 18 19 19A 19B 20 21 21A 22 22 23
Qty. 2 1 1 1 3 1 2 2 2 1 1 1 1 1 1
20
5
13
4
16
21
Description 4-40 S/S NYLOK NUT RAMP CABLE W/BALL SHANK, BHSCS 5/16-18 X 7/8 5/16-18HX JAM Z 5/16-18 FLAT NYLON WASHERS CB 10AMP RESETTABLE HCS 3/8-24 X 1 YZ8 3/8 HI-ALLOY L/W YZ 3/8 USS F/W Z WOODRUFF KEY, 3/16X3/4 FLAT BOTTOM PICK UP ARM (RAMP) 1/4-20X3/8 CUP POINT SET SCREW 5/16-18X1 3/4 FHSCS 5/16-18X1 3/4 FHSCS* 5/16-18HX JAM Z COVER RAMP NEW GENERATION
7
21A
14
17
15
Part # 1170854 RLXR1100 24070 1137023 76062 CB-PM3-10 18834 1133893 1133008 N/A RLXR2005 (INCLUDES SET SCREW) N/A 1124259 1124259 1136204 10068 * For motor bar ramps only
22
RLXR1000-04-OTC / RLXR1000-04-MB / RLXR1000-04-NARROW-MB
Folding Ramp Replacement Parts
Item 1 2 3 4 5 6 7 8 9 10
10
Qty. 1 1 3 3 3 3 6 2 2 2
Page 50
3
Description RAMP STANDARD (RAMP NARROW) RAMP CABLE W/BALL SHANK, CLAMP INSULATED 3/8" 1/4-20 X 1/2 BHSCS 1/4-20 NTE JAM NYLOK 10-32 X 3/4 BHSCS #10 SAE F/W Z 1/4 HI-ALLOY L/W YZ 3/8 USS F/W Z 3/8-16 YZ8 NE NYLOCK
4
2
9
14
5
12
Part # RLXR3000 (RLXR3000N) RLXR1100 8863T13 1124049 1137020 1124042 1133074 1133891 1133008 1137185
7
6
Item 11 12 13 14 15 15 15 16 17
RLXR1000-04-OTC / RLXR1000-04-MB / RLXR1000-04-NARROW-MB
Qty. 1 12 1 1 4 4 1 0.4 1
8
11
13 15
Description HCS 1/4-20X1/2 YZ8 QPA #10-32X3/8 BUTTON HEAD SOCKET CAP SCREW HINGE, RAMP FOLDING CABLE GUIDE (ROUND DISC) RIVETS* #4 sae 5/16od z f/w RUBBER BULB SEAL BACK FOAM* ANTI-RATTLE RUBBER URETH FOR (Motor Bar Only)* HINGE UPPER RAMP FO PAINTED
9
10
1
Part # 0115001 N/A RLRX3006ASM RLXR1025 97517A130 1133066 NX504B1 27036 RLXR1007 * Not shown
16
17
Folding Ramp Replacement Parts
Folding Ramp Adjustment Process
Page 51
Folding Ramp Motor Install / Ramp Removal Instructions Folding Ramp Motor Install (steps 1—19) Ramp Removal Instructions (steps 1-4 + 15-19) 1. Remove carpeted motor panel. This is held on by two Phillip head screws. 2. Disconnect wires going to limit switches and motor. 3. Unbolt ramp. There are two bolts (3/8) that go into the side of the van above ramp motor and two nuts (3/8) on the floor of the van-one nut is by the motor and one nut is by b-pillar. 4. Remove ramp from van. 5. Extend ramp so it is laying flat. 6. Remove roller from pick up arm. Also, remove cable bolt. 7. Remove set screw from pick up arm. Then insert 5/16 bolt into pick up arm to pull pick up arm off of motor shaft. If this does not work, cut motor shaft with a saw and punch out scrap piece from pick up arm. 8. Remove limit switches off of ramp. 9. Take out the four Allen head bolts (3/16) holding ramp motor. Remove motor. 10. Insert new motor. Reinstall the four Allen head screws with lock tight. 11. Reinstall limit switches. 12. Remove cams off of old motor and install on the new ramp motor. You will need to adjust these cams at step 16. 13. Reinstall pick up arm. Line up pick up arm and key way. Ensure Woodruff key is all the way inserted into the pick up arm. 14. Reinstall set screw (3/16) with lock tight. 15. Reinstall ramp in the van. Secure ramp with original hardware. 16. Install wiring for limit switches and motor. 17. Adjust ramp cams. Refer to Ramp Adjustment Instructions. 18.Test ramp for proper limit switch adjustment. 19.Reinstall carpeted motor cover.
Page 52
Folding Ramp Motor Install / Ramp Removal Instructions
Page 53
Rear Heat & Air
Low pressure AC line 2004 #B2102 2005 #B05101 2006 # B06101
High Pressure (3/8) AC line 2004 #B2101 2005 #B05100 2006 #B06100
Rear heat lines #B2100
AC Lines to AC Unit using O ring. Torque to 110 in-lb Rear heat lines #B2100
Page 54
Suspension
Shackle extensions #B2016 #B05020
Not used on 10” In The Floor vans
Welded OEM nut (from OEM seatbase). Reuse OEM shock bolt and washer. Folding ramp vans—OEM shocks
In The Floor van shocks #YB1844182
Trailer Tow Prep van shocks (not shown) #58620HD
Page 55
OTC System - 6.0 After 3/21/07 DASH RESET SWITCH (8/21/06)
USER KNEEL DISABLE ROCKER SWITCH AND WIRE HARNESS (ASM #03220-001)
DB / YL (20 GA.)
VT (20 GA.)
BK (20 GA.)
N/C
4
N/C
VT (20 GA.)
YL / BR (20 GA.)
1
1=OFF 2=UNLOCK 3=LOCK 2
DB / YL (20 GA.)
BLACK
13K 3
2
TAP TO OEM VT / LG
3
2K
DB / YL (20 GA.)
BK (10 GA.)
1
3.3K
PASSENGER DOOR LOCK SWITCH
WT / RD (20 GA.)
BK (20 GA.)
RIGHT PASSENGER DOOR SWITCH UNLOCK CONTROL
WT / RD (20 GA.) DB (20 GA.) VT / BL N / C 1
DB (20 GA.)
PK / WT (20 GA.)
N/C
DG (20 GA.) OR / RD (20 GA.) VT / YL (20 GA.) RD / DG (20 GA.)
RD / DG
RD / WT (20 GA.) 14
YL / DG (20 GA.)
N/C
RD / WT (20 GA.)
YL / WT (20 GA.)
BLACK
RD (20 GA.) RD / BK (20 GA.) YL / BK (20 GA.) YL / RD (20 GA.)
1
OR / DB (20 GA.) OR (20 GA.) RD / DB (20 GA.)
12
BK
B-PILAR SWITCH
BK
YL (12 GA.)
TAP TO OEM VT / YL
REL J1
YL / DG LIMIT SWITCHES WITH WIRE HARNESS KNEEL (ASM #03220-003)
UP LIMIT NO
BK
YL / WT
YL / WT
OR
COM
GY (12 GA.)
DB (20 GA.) HIGH FLEX OR (20 GA.) HIGH FLEX RD (20 GA.) HIGH FLEX
RD (12 GA.)
BK
DWN LIMIT NO COM
YL / DG
BLACK
RD / DB YL / BK YL / RD RD / BK RD
YL / BR (20 GA.) WT N / C
BLACK
BK (12 GA.) RD (12 GA.) YL (12 GA.)
Page 56
OTC System - 6.0 After 3/21/07 ROLLX USER SWITCHES SWITCH AND WIRE HARNESS (ASM #03220-005)
BK (20 GA.)
DB (20 GA.)
BK (20 GA.)
DB (20 GA.)
POWER OVERRIDE SWITCH IN THE FLOOR RAMP ONLY (FRONT PASSENGER DOOR JAM) OUT
DB (20 GA.)
DB (20 GA.)
BK (20 GA.) HIGH FLEX BK (20 GA.)
BK (20 GA.)
BK (20 GA.)
INSTALL 1 AMP ATO/ATC AUTOMOTIVE FUSE FOR EACH
RD (20 GA.)
RD (8 GA.)
BK (20 GA.)
WT / RD
IN RD (20 GA.) HIGH FLEX
FUSE PANEL (BEHIND GLOVE BOX)
OR (20 GA.) HIGH FLEX
BK (20 GA.)
DB (20 GA.)
DASH
C-PILAR
REAR PANEL
DB (20 GA.) HIGH FLEX
BK (8 GA.)
BK (10 GA.)
RD (8 GA.)
BK (8 GA.)
BATT
RD / WT (20 GA.)
NO COM
RD / DG (20 GA.)
BK (20 GA.)
ONE TOUCH SYSTEM REMOTE KEYLESS ENTRY (RKE) ROLLX RKE REMOTE MODULE
RD (20 GA.)
RD (12 GA.)
RAMP
LAY PANEL #06300-001
IGNITION
R
N
OR / RD
87A
30
BK / WT VT / YL TAP TO OEM BK / DG
DOOR
DETAILED DIAGRAM #07017-001 - ITF #07018-001 - FOLDING BK / WT
VT / YL BK (10 GA.)
87
GRN TAP GRN/GRY
85
86
D 2
DOOR CONTROL RELAY
OR / DB
TAP TO OEM PK / WT
NEUTRAL SAFE
P
BK (12 GA.)
YL (12 GA.)
J2
RD (12 GA.)
PK / WT (20 GA.)
RD (10 GA.)
BK (12 GA.)
BK (12 GA.)
POWER OVERRIDE BUS
DB (20 GA.) BK (20 GA.) RD (20 GA.)
LIMIT SWITCHES WITH WIRE HARNESS (FOLDING RAMP ASM #03220-004) (ITF RAMP ASM #03220-004A) UP LIMIT DOWN LIMIT COM NO
INLINE MINI AUTOMOTIVE FUSE HOLDER (40 AMP)
FOLDING RAMP - BLUE WIRE ITF RAMP - ORANGE WIRE
Page 57
OEM HARNESS
DOOR SNAKE
FR - BL ITF - BL + RD
OTC System - 4.05 and 6.0 Before 3/21/07
Page 58
OTC System - 4.05 and 6.0 Before 3/21/07
WT / RD
Page 59
Passenger Door Snake - In The Floor Ramp TO ROLLX CONNECTOR IN DOOR
CHRYSLER RIGHT SIDE DOOR CONTROLLER (IN DOOR)
RD (20 GA.) #PO1575
DB (20 GA.) #PO1546
OR (20 GA.) OEM OR (20 GA.) OEM #A1448-ND - FEMALE CONNECTOR #A1439-ND - SOCKET
#A1449-ND - MALE CONNECTOR #A1438-ND - PINS
ORIGINAL CHRYSLER DOOR OPEN SWITCH (RELOCATED FROM PAWL TO DOOR)
OEM BLACK CONNECTOR
TO OEM CONNECTOR IN DOOR #N05028ASM DOOR OPEN LIMIT SWITCH BRKT ASM (INCLUDES BRACKET)
#38042 - BLACK CONNECTOR #30034 - PIN ROLLX ADDS 6.2 FEET OF HIGH #39000 - CABLE SEAL FLEX ORANGE WIRE
#05089-001 DOOR OPEN SWITCH ASM, 3 TOWER (DOES NOT INCLUDE BRACKET)
OR #PO1576
N / O OR / RD (20 GA.) #3017
DB #PO1546
OR / RD (20 GA.) #3017 OR (20 GA.) #3010
RD #PO1575
COM
#SW429-ND SWITCH LEVER SPDT .1A
Rollx Part # OEM Snake #
Rollx Part # OEM Snake #
Foldout Ramp or 8 Inch ITF Ramp #07018-001 4874 122AE Foldout Ramp or 8 Inch ITF Ramp w/ Side Curtain Airbags (SCA) #07018-002 4874 484AD
10 Inch ITF Ramp #07017-001 4874 122AE 10 Inch ITF Ramp w/ Side Curtain Airbags (SCA)
OEM GREY CONNECTOR (GREEN IF VAN HAS SIDE CURTAIN AIRBAGS)
#07017-002 4874 484AD
TO FRONT DASH
#LCP625 - LOOM 5/8
Page 60
Passenger Door Snake - In The Floor Ramp TO ROLLX MAIN HARNESS (DOOR OPEN INPUT)
OR / RD (20 GA.) #3017
ROLLX ADDS 7.7 FEET OF RED AND BLUE HIGH FLEX WIRE #A1449-ND - MALE CONNECTOR #A1438-ND - PINS
RD (20 GA.) #10616 #10223 - RING CONN BLUE 3/8’
DOOR CONTROL RELAY “B” PILLAR #5-1393302-8
OR / DB (20 GA.) #2033
BK / RD #2007 BK / VT #2015 BK / WT #2016 BK / LB #2013 BK / BR #2010 BK / DG #2011 BK #10592
Page 61
“B” PILLAR
BK / DG (20 GA.) #2011 ROLLX EXTENDS ALL 7 OEM WIRES INSIDE PLASTIC TUBING 7 FEET EXCEPT THE BL / WT WIRE THAT IS EXTENDED 10 FEET
BK / WT (20 GA.) #2016
#11208 - LOOM 1/4
TO ROLLX MAIN HARNESS (DOOR DISABLE OUTPUT)
TO ROLLX MAIN HARNESS (DOOR CLOSE INPUT) OR (20 GA.) #PO1576
BK / RD (16 GA.) OEM BK / VT (20 GA.) OEM BK / WT (20 GA.) OEM BK / LB (20 GA.) OEM BK / BR (20 GA.) OEM BK / DG (20 GA.) OEM BK (16 GA.) OEM
VT / YL (20 GA.) #2040
DB (20 GA.) #PO1546 RD (20 GA.) #PO1575
TO FUSE PANEL (POWER)
#A1448-ND - FEMALE CONNECTOR #A1439-ND - SOCKET
ROLLX “T” TAPS INTO BK / GN WIRE WITH 2 FEET BK / GN WIRE
Passenger Door Snake - Folding Ramp TO ROLLX CONNECTOR IN DOOR
CHRYSLER RIGHT SIDE DOOR CONTROLLER (IN DOOR)
DB (20 GA.) #PO1546
OR (20 GA.)
ROLLX “T” TAPS INTO OEM ORANGE WIRE WITH ROLLX ORANGE WIRE #A1448-ND - FEMALE CONNECTOR #A1439-ND - SOCKET
ORIGINAL CHRYSLER DOOR OPEN SWITCH (RELOCATED FROM PAWL TO DOOR)
#A1449-ND - MALE CONNECTOR #A1438-ND - PINS
OEM BLACK CONNECTOR
TO OEM CONNECTOR IN DOOR
Rollx Part # OEM Snake #
Rollx Part # OEM Snake #
Foldout Ramp or 8 Inch ITF Ramp #07018-001 4874 122AE Foldout Ramp or 8 Inch ITF Ramp w/ Side Curtain Airbags (SCA) #07018-002 4874 484AD
T
D
OEM GREY CONNECTOR (GREEN IF VAN HAS SIDE CURTAIN AIRBAGS)
TO FRONT DASH
#LCP625 - LOOM 5/8
Page 62
BK / RD (16 GA.) BK / VT (20 GA.) BK / WT (20 GA.) BK / LB (20 GA.) BK / BR (20 GA.) BK / DG (20 GA.) BK (16 GA.)
#20 #20 #20 #20 #20 #20 #10
Passenger Door Snake - Folding Ramp TO ROLLX MAIN HARNESS (DOOR OPEN INPUT)
OR / RD (20 GA.) #3017
#A1448-ND - FEMALE CONNECTOR #A1439-ND - SOCKET
ROLLX ADDS 7.7 FEET OF RED AND BLUE HIGH FLEX WIRE
DB #PO1546 #A1449-ND - MALE CONNECTOR #A1438-ND - PINS
VT / YL (20 GA.) #2040 BK / DG (20 GA.) #2011
TO FUSE PANEL (POWER)
TO ROLLX MAIN HARNESS (DOOR DISABLE OUTPUT)
RD (20 GA.) #10616
DOOR CONTROL RELAY “B” PILLAR #5-1393302-8
#10223 - RING CONN BLUE 3/8’
BK / WT (20 GA.) #2016
ROLLX EXTENDS ALL 7 OEM WIRES INSIDE PLASTIC TUBING 7 FEET EXCEPT THE BL / WT WIRE THAT IS EXTENDED 10 FEET
OR / DB (20 GA.) #2033
007 015 016 013 010 011 0592
Page 63
“B” PILLAR
TO ROLLX MAIN HARNESS (DOOR CLOSE INPUT) DB (20 GA.) #PO1546
BK / RD OEM BK / VT OEM BK / WT OEM BK / LB OEM BK / BR OEM BK / DG OEM BK OEM
ROLLX “T” TAPS INTO BK / GN WIRE WITH 2 FEET BK / GN WIRE
Rollx Power Door System
Rollx Power Door (Moto
10 AMP CIRCUIT BR OR 15 AMP GLASS F
VT (14)
85
87
PK (14)
OEM VT/DG (14) FOR DOOR AJAR
ON
BUTT CONNECT
BK (14)
WT (14)
BR (14 GA.) YL (14 GA.) DG (14 GA.)
OFF
FUSE 15 A
KNEEL
26 24 25
TN (14 GA.)
RD (10 GA.)
OPEN
CLOSE
RD (10)
OPEN
NEUTRAL SAFETY
NC NO COM
RAMP POWER SWITCH
DASH KNEEL DOWN L.E.D.
RD (14)
FUSE 30 A
RMP DWN
DASH USER SWITCH #8981K520 DOOR
BR
NC NO COM
DOWN LIMIT SWITCH
13 11 12
DG (14)
RAMP UP LIMIT SWITCH
C USE
DB (14 GA.)
87A
BK (16 GA.)
WT (14 GA.)
86
RAMP
VT (16 GA.)
30
BR (14 GA.)
BK (14)
RD (14 GA.)
RD (14)
YL (14) YL (14 GA.)
RD (16 GA.)
ROLLX REMOTE (BEHIND GLOVE BOX)
BK #8
VT #2
PK #3
RD #1
TOUCHTRONICS MODULE
CLOSE
NC NO COM
DOOR LOCK LIMIT SWITCH #6X284 IN PASSENGER DOOR (WHEN CLOSED, SENDS POWER TO HARDWIRED SWITCHES)
KNEEL ON/OFF SWITCH #8981K519 GY (16 GA.) GREY WRAP
BK (14) WT (14) 30
86
87A
87A 87
FIREWALL
30
85
87
RD (14 GA.) BK (14 GA.)
DOOR OPEN
Page 64
DOOR
LOC
Rollx Power Door System
or Bar) Wiring Diagram
REAKER
FUSE YL (16 GA.) TO OEM DOOR AJAR NC VT (14) NO
MOTOR BAR
DG
KNEEL UP LIMIT SWITCH
NC NO NC NO COM
COM
TN (16 GA.)
TO DASH JONES BLOCK L.E.D. DG 6 5 YL 4 3 2 1 KNEEL DN LIMIT SWITCH
CLOSE
30
86
87A 85
86
87A 87
85
30
WT (16 GA.) 86
87A 87
85
87
85
DG (16 GA.)
87
30
YL (16 GA.)
86
BR (16 GA.)
30
OR (16 GA.)
YL (14 GA.)
87A 85
YL (14 GA.)
BK (14 GA.)
GY (14 GA.) 86
PK (14 GA.)
BR (16 GA.)
RAMP DOWN
RAMP UP
KNEEL DOWN
RELAYS (#5-1393302-8)
KNEEL UP
CATED IN OEM SPARE TIRE KIT COMPARTMENT Page 65
YL
KNEELER
GY (16 GA.)
YL (16 GA.)
12 11 13
BR
WT
RD (16 GA.)
COM
DG
H
COM
NC NO
YL
RD
#310-1059
DOOR OPEN LIMIT SWITCH (CHERRY) #E19-50H
BR
C PILLAR ER SWITCH
NC NO COM
DG (16 GA.)
DB
DOOR
13 11 12
BR(16 GA.)
Occupant Control Module / Seat Sensor Resistors
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Power Seats - Driver with Power Only
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Power Seats - Driver with Power and Heat
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Power Seats - Passenger with Power and Heat
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Power Seats - Driver with Memory
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Power Seats - Driver with Memory
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Maintenance Information Doors Door track - Periodically make sure lower door track is free of debris and vacuum track out. Make certain to clear out any water and ice that may be present.
Rollx power door (If equipped) - Every 6 months lube the gear rack (bar) with a high quality white lithium grease. Make sure to clean off any old grease first.
Kneel System Kneel chain - Every 6 months spray the chain inside the rubber boot with a high quality oil to lubricate and protect.
Ramps Folding ramp - Every 6 months spray the ramp’s lower and upper hinge with high quality silicon lubricant.
In The Floor ramp - Every 6 months spray the ramp access cover’s flap hinge with a high quality silicon lubricant.
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Warranty New Rollx Van Warranty Coverage Information Rollx Vans provids a limited warranty on its minivan against defects in material or workmanship for a period of 3 years or 36,000 miles, whichever comes first. For warranty specifics please refer to an Owner’s Manual or contact Rollx customer service. For all warranty or reimbursement needs, you must have prior authorization by the Rollx Service Department. 1.
Call 1-800-956-6668, and a Rollx Customer Service Representative will assist you in any concerns or issues you have with your van.
2.
The service representative will evaluate what repair is needed, and either set up an appointment with an “At Home” service technician or direct you to a nearby service facility. An authorization number must be issued.
Rollx will work with many repair facilities. Rollx reserves the right to approve a repair shop or recommend an alternative. Rollx may request that defective parts be returned to our customer service department for inspection. If defective parts are found to be defective because of abuse or neglect, reimbursement for the new replacement parts may be denied. Rollx reserves the right to use rebuilt components. Rollx will ship all warranted replacement parts by nationwide carrier. In most cases, shipment will be by ground transport and absorbed by Rollx. Any other mode of transportation will be at the expense of the customer.
Our Mission To improve the quality of life of people with disabilities of all income levels by delivering the best modified vehicle. We intend to keep that customer for life by following up with a level of service that exceeds all of their expectations. Our Values Quality • Compassion • Honesty • Integrity • Fairness
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